Đang tải... (xem toàn văn)
HACCP COOKED PDTO ,PD SHRIMP
ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY FOREWORD T − here are many different systems of quality management applied in industrial production in the world nowadays They are, namely, GMP, HACCP, ISO 9000 and TQM Every system has its own distinctive features and approaches Seafood producers in the country as well as our ABC Company often face these questions: Which quality management system should be chosen for our business? Which of those systems is suitable for the quality of our product in our specific economic conditions? Which of them can really suit us to meet customers’ demand for qualified, hygienic and wholesome products and hence win their acceptance and credence ? Food in general and food produced from aquatic fauna in particular have this same characteristic: They spoil soon And they will spoil easily If some technical steps during the processing course fail to be properly monitored, the product would turn out to be harmful to customers, and the manufacturer may have a chance to witness the demise and their reputation as well Therefore, quality management in food processing is a decisive matter and must be strictly realized from the first step of material collecting to the finished products to ensure their best quality Customers are now demanding quality instead of quantity of products As for foodstuff, quality is crucial not only to determine whether a product could find its feet in the market but also to expose the responsibility of a conscientious producer to the society Anyway, to solve the quality problem, it demands much effort in renewing the way of our economic thinking as well as in improving mechanism of our management In addition, investment in modern equipment and instruments for production should be further enforced Since having acquired necessary conditions, our ABC Company has drastically applied the GMP system in our production activities The approaches have brought us remarkable initial results However, we wish to go further in making our products better and more competitive We have decided to seek helps from The Ministry of Fisheries The Ministry then helped us, and other businesspersons who had registered to export their products to EU & USA markets, to put the HACCP into effect in our processing activities In this document, we are building a technological process for producing FROZEN IQF COOKED SHRIMP PRODUCTS – PDTO, PD ABC HACCP-2009 ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY ABC COMPANY ***** THE SOCIALIST REPUBLIC OF VIETNAM Independence - Freedom -Happiness ***** Ref NO:07/QDCTY/2009 ABC, Jan 01 st , 2009 DECISION OF DIRECTOR OF ABC ( MODIFICATION ON TEAM OF HACCP BASED PROGRAM FOR QUALITY MANAGEMENT FOR FROZEN IQFCOOKED SHRIMPS PRODUCTS – PDTO, PD) - In reference to Decision No: 105/QD/UB dated on 28th September, 1992 issued by Minh Hai Province People's Committee on the establishment of the company - Based on the business license No: dated on 09th October, 1992 and ratified by Minh Hai Province economic Arbitrator - Based on Decision No: 02/QDCTY.97 dated on 30th November, 1997 issued by Director of Company - According to the directions of the Ministry of Fisheries & NAFIQAVED for all enterprises in need of exporting to seafood to U.S.A & EU markets - Considering the proposals of QC Chief DECIDES Articles 1: Modification on the Team of HACCP-based program for quality management for Frozen IQF Cooked shimps products – PDTO, PD Article 2: All concerned divisions and the members in the HACCP Team have responsibilities for developing and implementing the regulations as mentioned in "responsibilities, functions, duties and rights of HACCP Team" Article 3: All concerned divisions and the members as mentioned in the list must carry out this decision This decision is validated from the signing date ABC Co C/c: - Boarding Directors - General professional Division - HACCP Team - All production groups - Kept by Administrative Dept., HACCP records ABC COMPANY ***** HACCP-2009 THE SOCIALIST REPUBLIC OF VIETNAM Independence - Freedom -Happiness ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY ***** Ref NO:08/ QDCTY/2009 ABC, Jan 01 st , 2009 DECISION OF DIRECTOR OF ABC ( PROMULGATION ON HACCP BASED PROGRAM FOR QUALITY MANAGEMENT FOR FROZEN IQF COOKED SHRIMPS PRODUCTS – PDTO, PD) - In reference to Decision No: 105/QD/UB dated on 28th September, 1992 issued by Minh Hai Province People's Committee on the establishment of the company - Based on the business license No: dated on 09th October, 1992 and ratified by Province Minh Hai economic Arbitrator - Based on Decision No: 02/QDCTY.97 dated on 30th November, 1997 issued by Director of Company - According to the directions of the Ministry of Fisheries & NAFIQAVED for all enterprises in need of exporting to seafood to U.S.A & EU markets - Considering the proposals of QC Chief DECIDES Article 1: This decision is promulgated together with HACCP-based program for quality management for Frozen IQF Cooked shrimps products - PDTO, PD Article 2: The HACCP team is responsible for developing and implementing production reality on approved program Article 3: The HACCP team should hold monthly meeting and record on writing the implementation program, and give comments for modification Article 4: The HACCP team and concerned divisions have responsibilities for implementing this decision This decision is validated from the signing date DIRECTOR OF ABC C/c: - Boarding Directors - General professional Division - HACCP Team - All production groups - Kept by Administrative Dept., HACCP records HACCP-2009 ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY THE MEMBERS IN HACCP TEAM NO MEMBERS Professional Levels Engineer of food processing Positions - Vice - Director - Production manager Engineer of food technology Staff of quality control department TRAN MINH HOANG (Chief) LY THE CUONG (Member) TRAN THANH BINH (Member) Intermediate Technician Chief of technical department NGUYEN THI MAI (Member) Bachelor of biochemistry Deputy chief of sales department Bachelor of biochemistry Staff of quality control department Intermediate processing degree of fishery Staff of quality control department Bachelor of administration business Engineer of food processing Deputy production manager Chief of QC THACH HOANG VU (Member) TRAN THANH BANG (Member) PHAM THI RA (Member) NGUYEN TRONG PHAN (Member) HACCP-2009 Responsibilities - Selecting and developing HACCP plan - Verifying the HACCP implementation plan and submitting to Director for approval - Co-ordination relative activities to support HACCP team * Responsible for HACCP implementation - Setting up and adjusting quality management programs: HACCP, GMP, SSOP - Training workers Responsible for implementation of quality management program - Making operation plans for HACCP team Responsible for maintenance and upgrading of processing conditions (equipment, instrument and workshop) Responsible for implementtation of sales - Responsible for taking samples for microbiological tests - Making reports of micro-biological results to Boarding Directors - Collecting reports to Director Boarding - Responsible for controlling raw material quality Responsible generally for workshop Quality control of product ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY Cai doi vam Town – Phutan District – Camau Province – Vietnam TEL: 84 – 07803- 889050/1/2/3/4 FAX: 84-07803 889067 E-mail: ABC@hcm.vnn.vn ABC COMPANY ***** THE SOCIALIST REPUBLIC OF VIETNAM Independence - Freedom -Happiness ***** - RESPONSIBILITIES, FUNCTIONS, DUTIES AND RIGHTS ASSIGNED TO HACCP TEAM I/ - GENERAL RESPONSIBILITIES: Director of Company: The Company Director is responsible for all company activities, appoints HACCP Team's members, considers and approves the company HACCP Plan, co-ordinates and manages all concerned activities which mutually help HACCP Team, summits HACCP plan to the competent authority for their check and confirmation Vice Director ( Production manager ) is in charge of detailed HACCP plan, submits HACCP plan to the Director for his approval, receives all reports, and verified all activities periodically or at random The control department (QCs) takes in HACCP team, gives often comments, updates information and modifies it if necessary, considers all comments, confirms the truthfulness of the information, checks all quality program, and trains employees in programs related to HACCP plan HACCP team consists of experts in many fields relating to production, such as industry, biology, healthcare, instrument techniques, economics, construction…, etc HACCP team is responsible for establishing, updating, modifying all programs relating to HACCP plan, training employees in programs relating to HACCP, and submitting them to the Director for approval Employees are trained, of high-qualification, abided with the regulations at their working places, and fulfil all tasks assigned by HACCP plan II FUNCTIONS, DUTIES, AND RIGHTS OF HACCP TEAM: Functions: HACCP team is a part of the company quality control department, supervises the overall product quality management based on HACCP plan, and is managed by the quality control department and the Boarding Directors of company Duties: - Satisfy all requirements of the Director, develop and implement HACCP plan - The implementation of HACCP plan should be considered by the quality control department and approved by the Director HACCP - 2009 ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY Cai doi vam Town – Phutan District – Camau Province – Vietnam TEL: 84 – 07803- 889050/1/2/3/4 FAX: 84-07803 889067 E-mail: ABC@hcm.vnn.vn - Gives comments on products quality management to the quality control department and the company Director - Take part in activities to effectively implement the quality management based on HACCP plan - Report personnel organisation and other concerned activities of HACCP team to the quality control department and the Director periodically or at random, according to their requirement Rights: - Give comments on necessary problems relating to the effective implementation of HACCP - based plan for quality management to the quality control department and the Director - Require officers and employees abide with the HACCP team regulation approved by the Director - Attend workshops, training courses under the direction of the company Director - Give ideas to the company Director about the promotion, the dismissal, the reward, and the punishment of the team's members DIRECTOR OF ABC C/c: - Boarding Directors - General professional Division - HACCP Team - All production groups - Kept by Administrative Dept., HACCP records HACCP - 2009 ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY Cai doi vam Town – Phutan District – Camau Province – Vietnam TEL: 84 – 07803- 889050/1/2/3/4 FAX: 84-07803 889067 E-mail: ABC@hcm.vnn.vn LIST OF EQUIPMENT No I II Names and kinds Freezing Equipment - IQF Conveyor belt - Cooking and chilling Conveyor belt - Contact Freezer (1000 KGS) - Contact Freezer (1500 KGS) - Contact Freezer (500 KGS) - Contact Freezer (500 KGS) - Contact Freezer (800 KGS) Making countries JAPAN VIETNAM HASEGAWA (JAPAN) MYCOM (JAPAN) HASEGAWA (JAPAN) HASEGAWA (JAPAN) HASEGAWA (JAPAN) Capacity Quant ity Year of use 400KGS/hour 700 KGS/hour 01 01 2001 2001 01 01 01 03 01 1988 1983 1988 1990 1997 640 KGS/Batch 960 KGS/Batch 320 KGS/Batch 320 KGS/Batch 500 KGS/Batch Equipment Use For Storage of Products - Cold Store - Raw Material Store - Pre-Freezing Store Equipment use for making ice IV V - Workshop 50T/day - Workshop 30T/day - Flake-ice Workshop 16 N/day - Flake-ice Workshop 17 N/day Electric Equipment use for Production - KONASUTA 340 KVA - KONNASUTA 100 KVA - CATERDILLIAR 400 KVA - CATERDILLAR 500 KVA - CUMINIS 340 KVA - CUMINIS 1000 KVA HASEGAWA (JAPAN) HASEGAWA (JAPAN) HASEGAWA (JAPAN) HASEGAWA (JAPAN) HASEGAWA (JAPAN) Denmark JAPAN 100 tones/Store 75 tones/Store tones/Store 50 tones/ Day 30 tones/ Day 10 tones/ Day 1988 1988 01 01 01 340 KVA 100 KVA 400 KVA 500 KVA -18oC ÷ -25oC -18oC ÷ -25oC +5oC ÷ -5oC 1988 1990 Foreig n Foreig n Foreig n Foreig n 10 tone/day JAPAN JAPAN U.S.A U.S.A U.S.A U.S.A 2h50' 3h50' 2h50' 2h50' 2h50' 2001 01 02 01 01 01 01 Notes 1988 1997 1997 01 III 02 01 01 Technical characteristi cs 1 HACCP - 2009 ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY Cai doi vam Town – Phutan District – Camau Province – Vietnam TEL: 84 – 07803- 889050/1/2/3/4 FAX: 84-07803 889067 E-mail: ABC@hcm.vnn.vn VI Facilities Use For Water Supply - ϕ 250 - ϕ 110 - ϕ 90 - Hydraulic pump - Water treating Chlorine pump - 569 KVA transformer Production upportingEquipm ent - Washing machine - Cord twister - Metal machine 340 KVA 1000 KVA JAPAN JAPAN JAPAN JAPAN JAPAN JAPAN 30 m3/h 30 m3/h m3/h 50 m3/h 60 m3/h 02 19972001 JAPAN TAIWAN JAPAN 15 tone/ day ORGANISATIONAL FLOW CHART HACCP - 2009 ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY Cai doi vam Town – Phutan District – Camau Province – Vietnam TEL: 84 – 07803- 889050/1/2/3/4 FAX: 84-07803 889067 E-mail: ABC@hcm.vnn.vn FOR QUALITY MANAGEMENT Director Production Manager Technical Division Quality Control Division Supply Division Production Management HACCP Team Micro-biological Test Technology and Product Outlook Water Treatment Ice Flakes Production Raw Material Receiving Ice Block Production Collecting Spot Agent Sanitary Team Packaging Material Store Receiving Team Chemical Store Primary Processing Material Preserving Store Processing Quick Freezing PROCESS FLOW CHART Product Storage Packing NAME OF PRODUCTS: FROZEN IQF COOKED SHRIMP PRODUCTS – PDTO, PD HACCP - 2009 ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY Cai doi vam Town – Phutan District – Camau Province – Vietnam TEL: 84 – 07803- 889050/1/2/3/4 FAX: 84-07803 889067 E-mail: ABC@hcm.vnn.vn RAW MATERIAL RECEIVING CCP1: -Antibiotic 1st WASH RAW MATERIAL KEPT REFRIGERATED PROCESSING (PDTO, PD) ND WASH SIZING AND GRADING 3RD WASH SOAKING IN SOLUTION OF PHOSPHATE & SALT TH WASH CHECK FOREIGN MATTER TRAY LAYING STEAMING CCP2: Temperature of cooking COOLING & CHILLING FREEZING WEIGHING GLAZING RE-FREEZING PAKING METAL DETECTING CCP3: Metal fragments COLD STORAGE SHIPPING Date of verification : 01/01/2009 (Signature) 10 HACCP - 2009 ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY (1) STEAMING (2) (3) Pathogenous Bacterial surviral Cai doi vam Town – Phutan District – Camau Province – Vietnam TEL: 84 – 07803- 889050/1/2/3/4 FAX: 84-07803 889067 E-mail: ABC@hcm.vnn.vn - Cooking time range is from 90 to 120 seconds depending on each shrimp size (4) - Shrimp size and time of cooking for each size - Minimum temp of cooking until 100oC Temperature of cooking until - Shrimp is cooked until internal temperature gets 72oC - Internal temperature of shrimp (5) (6) (7) (8) - Monitiring of cooking time by Stopwat - Monitoring shrimp size by electric scales - Visually monitoring the cooker by air Temperature gauge - Monitoring internal Temperature of shrimp by thermometer - Monitiring cooking time (conveyor Speed), at the sart of each shrimp size and at least once an hour thereafter - Monitoring internal shrimp Temperature every fifteen ( 15) minutes - Monitiring the cooker air Temperature every fifteen ( 15) minutes - Q.C technician will visually check the recorder data at the end of cycle for cooking time and temp - Q.C technician will monitor the temp Of shrimp before being cooked and the internal temp Of shrimp just finished cooking - Adjusting cooker temperature - Extending the cook time - Segregating and holding the products for an evaluation of the adequacy of the cooking process If it is determined that the products has not received an adequate cook, the products should be destroyed, diverted to a nonhuman food use, or reprocessed to eliminate potential of pathogens or - Diverting products to a shrimp canning operation (9) Monitiring forms at Steaming step Thermometer & Scale calibration reports NUOCA reports and other related records (10) The chief of HACCP team has weekly review on all reports Every day, before starting, the thermometers and scale used that day should be compared against standard weigh and mercury in class thermometer Calibration is recorded in the reports 24 HACCP - 2009 ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY Cai doi vam Town – Phutan District – Camau Province – Vietnam TEL: 84 – 07803- 889050/1/2/3/4 FAX: 84-07803 889067 E-mail: ABC@hcm.vnn.vn (1) (2) Physical: Metal fragments METAL DETECTING (3) (4) (5) (6) (7) (8) No metal allbowed in which has dimension more Fe Ø =1.5 mm, Sus Ø =2.0mm in any products Supervision of presence of metal fragments in each lot of products Inspection of each product unit ( each IQF or each semiIQF) Metal detectors are checked with standard samples every 15 minutes Operator reponsible for checking finished products If metal is found, holding and segregating the products and then rejecting it Supervision of sensitivity of metal detectors Using the test samples to check sensitivity Q.C (Packing step) If metal detectors are not sensitized to recognize metal fragments, holding and segregating the lot, repairing machines and then all the lot of product will be rechecked (9) Monitoring forms at checking metal Corrective action reports (10) Q.C manager will weekly review and inform the staff wherever HACCP plan has modification Checking metal detectors daily with standard samples: Fe = 1.5 mm Sus = 2.0 mm Verification reports on metal detectors Date of verification : 01/01/2009 (Signature) 25 HACCP - 2009 ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY Cai doi vam Town – Phutan District – Camau Province – Vietnam TEL: 84 – 07803- 889050/1/2/3/4 FAX: 84-07803 889067 E-mail: ABC@hcm.vnn.vn VERIFICATION PROCEDURE OF HACCP PLAN I/ Elements of verification procedure: A Entire verification: Verification as usual: - Director boarding, Plant manager, HACCP Team leader will inspect the compliance with implementing and monitoring critical control points (CCPs) during production - Weekly, microbiological employees will take samples of final products for analysis - Once there is customer’s complaints, immediately verify all the problems related to critical control points (CCPs) which are being monitored or hazards have been existing and have not been controlled at CCPs - Weekly, will verify equipment, instruments monitored such as temperature recording thermometer, mercury thermometer, metal detector, chlorine concentration measurement device ) Verification of records: Verification after a week of recording + Monitoring at critical control points (CCPs): Whether the records are done fully in compliance with established requirements and adequate frequency or not + Taking corrective actions: Full records, handling accurate data, taking corrective actions in time + All records about equipment, device calibration as well as analysis of finished or intermediate products must be adequate Reassessment of the entire HACCP plan: - Every week , reassess the entire HACCP plan - Whenever the changes of raw materials, raw material source, processing systems and intended use occur, must reassess the entire HACCP plan B Corrective actions whenever the deviations occur compared with critical limits (CL): - Consider whether Corrective actions are taken as planed in HACCP plan or subject to other appropriate systems or not, whether the corrective action results are verified or not before shipment - Consider whether corrective actions related to customer’s complaints are necessary to be taken or not - Consider results after taking corrective actions C Reassessment of hazard analysis: Re-analysing hazard analysis whenever changes occur that can make the hazards change or new hazard appear must also be reassessed Date of Approval :01/01/2009 (Signature) 26 HACCP - 2009 .. .ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY ABC COMPANY ***** THE SOCIALIST REPUBLIC OF VIETNAM Independence - Freedom -Happiness ***** ... Independence - Freedom -Happiness ABC SEAFOOD IMPORT - EXPORT & PROCESSING JOINT STOCK COMPANY ***** Ref NO:08/ QDCTY/2009 ABC, Jan 01 st , 2009 DECISION OF DIRECTOR OF ABC ( PROMULGATION... OF ABC C/c: - Boarding Directors - General professional Division - HACCP Team - All production groups - Kept by Administrative Dept., HACCP records HACCP-2009 ABC SEAFOOD IMPORT - EXPORT & PROCESSING